Novel process for molecular rupture, reorganization and fuel optimization and volume increase through high pressure and hydrodynamic cavitation with the addition of water and other additives a.k.a. romo-apc

ABSTRACT

The present invention provides a molecular rupture and recombination of fuels with additives or fuel enhancers such as, but not limited to, non-hydrocarbon and/or hydrocarbon substances such as but not limited to, water, methanol, ethanol, naphtha, and other lighter fluids, through the use of a hydrodynamic cavitation apparatus or reactor to cause the molecular rupture, coupled to a high pressure system where the recombination of the molecules (fuel and additives) stably occur.

FIELD OF THE INVENTION

The present invention pertains mostly to the petrochemical sector. It relates to systems and methods for upgrading hydrocarbons and biofuels, mainly focused on the increase in fuel volume, fuel characteristics improvement, and refining or fractioning of fuels.

BACKGROUND OF THE INVENTION

Fuel is one of the most important security issues for a country. With decreasing reserves of light crude oil, and crude in general, our fuel supply is being affected; prices are at a high and will continue to escalate as oil sites are depleted. The petroleum industry is always looking for more economical ways to crack, distil, refine and improve on fuel characteristics. Recent environmental requirements for fuels to conform to EPA standards, and having the rest of the World following in the footsteps of these requirements, have prompted the industry to explore new methods to reduce these emissions in the least expensive manner.

The conventional process used in the petroleum industry for crude oil molecular rupture to obtain lighter fractions of fuel is thermal cracking. The thermal cracking is carried out under high temperature and pressure conditions using a catalyst, like Al₂O₃, with sophisticated equipment and require extensive footprint.

On the other hand, hydrocracking is a process used in the oil industry to convert low quality raw materials into higher-value fuel. This process is the best way to obtain a diesel fuel with lower sulphur content and aromatics. Normally the hydrocracking process is carried out using two suspended bed catalytic packed reactors that operate at high pressure and temperature. In the first reactor the molecule is ruptured, releasing sulfur and nitrogen, then the liquid fraction enters the second reactor where it is hydroisomerized and cracked. The hydrocracking process allows a variety of liquid fuels with certain undesirable characteristics to conform to existing environmental requirements.

These conventional processes have a high demand in energy and require large spaces for the process to take place, aside from the use of catalysts and other consumables which require periodical exchange or replacement. All this represents an added cost for the industry, especially now that we have to work with heavier fractions of crude oil. Aside from the previous downsides of current methods, none of the existing processes increase the volume of the fuel being treated.

SUMARY OF THE INVENTION

The present invention provides a novel system and method for fuel cracking and optimization.

According to an aspect of the invention, the system is a lower energy/power/heat consumption system.

According to another aspect of the invention, the method increases the fuel volume using non-expensive additives.

According to still another aspect of the invention, the method improves the API index.

According to one aspect of the invention, the system uses a reduced amount of floor area on a facility.

According to another aspect of the invention, the method provides a less expensive mechanism for delivering additives stably to fuel at a molecular level.

According to yet another aspect of the invention, the method creates cleaner fuels.

According to one aspect of the invention, the method reduces undesirable elements in fuel such as: sulfur, CO, Nox, Carbon particulate at the moment of combustion and Crude Oil viscosity.

According to another aspect of the invention, the method can be applied to biofuels as well as hydrocarbon fuels.

According to yet another aspect of the invention, the system can be used in-line with power generation devices at higher water/additive ratios.

According to one aspect of the invention, the method improves the heating value.

According to another aspect of the invention, the method increases the Cetane level in D6 and D2 fuels.

According to still another aspect of the invention, the method can increase the octane levels in lighter fuels.

According to yet another aspect of the invention, the method reduces associated system maintenance due to a cleaner combustion process.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying figures showing illustrative embodiments of the invention, in which:

FIG. 1 illustrates the molecular rupture and reorganization system, according to an embodiment of the present invention.

FIG. 2 illustrates a dosing, mixing and cavitation configuration, according to an embodiment of the present invention.

FIG. 3 illustrates an isometric view of the molecular rupture and reorganization system, according to an embodiment of the present invention.

FIG. 4 illustrates a hydrodynamic cavitation reactor system, according to a preferred embodiment of the invention.

FIG. 5 illustrates an isometric view of a water and additives tank system, according to an embodiment of the present invention.

FIG. 6 illustrates a fuel tank, according to an embodiment of the present invention.

FIG. 6A illustrates an isometric view of a fuel tank heating jacket, according to an embodiment of the present invention.

FIG. 7 illustrates a heat exchanger, according to an embodiment of the present invention.

FIG. 8 illustrates a dosing and mixing unit, according to an embodiment of the present invention.

FIG. 9 illustrates an example of the molecular rupture and polymerization, according to an embodiment of the present invention.

Throughout the figures, the same reference numbers and characters, unless otherwise stated, are used to denote like elements, components, portions or features of the illustrated embodiments. The subject invention will be described in detail in conjunction with the accompanying figures, in view of the illustrative embodiments.

DETAILED DESCRIPTION OF THE INVENTION

The method of the present invention, is based on the use of a hydrodynamic cavitation reactor coupled with a high pressure system in the presence of non-hydrocarbon or hydrocarbon additives, including but not limited to water, ethanol, and methanol, at various ratios, that allows the rupture and relocation of the molecules of any fuel, ostensibly improving its physical-chemical characteristics. As a result, when processing heavy fuels like D6 or D2 we obtain an increase in volume as well, with proven results of over 40% in volume increment. Regardless of the fuel refined by the method, the resulting fuel will always have better characteristics, since polymeric molecules are broken and rearranged, so that characteristics such as, for example, API in the case of crude oil, and flash point, Cetane level, and heating value in the case of diesel are substantially improved, among other treated fuels and improvements.

A hydrodynamic cavitation reactor is a device which reproduces the cavitation phenomenon or cavitation bubbles in the liquid; here a fluid is subjected to a strong change of pressure with the aim of achieving a phase shift among other functions. In the reactor, pressure reached is equal to the vapor pressure of the fluid, causing the formation of cavitation bubbles known as cavities. These reactors provide the formation of cavities, which in turn implode generating high frequency pulses that shock the fluid causing the rupture and reorganization of the polymer chains in the fuel to occur.

During the process of the present invention, the molecular rupture of the polymer chains forms what we call a “temporary active binding center”, also known as radical, which is ready to combine chemically with other organic or inorganic molecules. These active binding sites can be joined to other molecules present in the treated fuel by introducing foreign substances that are added during the process (referred to as additives). The additives can be any compound which improves the treated fuel characteristics and in some cases its resulting volume is also increased.

Any polymer chain fluid that is submitted to this strong pressure change suffers rupture and reorganization of its molecules. When the rupture occurs, unstable molecular “active” sites are formed and become available to be combined in situ with other molecules (additives). The formation of these active sites is what makes possible the reorganization and recombination of the fuel's molecules therefore improving the fuel's overall quality and characteristics.

Molecular rupture caused by the process of the present invention is used to add other molecular compounds that bind chemically to the treated fuel. For example water can be used to form a new polymer chain containing hydrogen and oxygen within its final structure. This process improves fuels such as but not limited to diesel, or bunker, by adding water in a certain predetermined percentage (we have tested at over 40%), increasing the volume of the finished product by the determined percentage, and even creating a new fuel with enhanced features and characteristics while remaining molecularly stable.

The physics and chemistry behind the process of the present invention is based on studies of the induced chemical reactions on inorganic and organic material after being submitted to ultrasound. In the process of the present invention, the ultrasound energy is replaced by the formation of cavities in the fluid due to the change in pressure induced by the hydrodynamic cavitation reactor. The high inlet pressure is violently reduced inside the reactor, causing a thermodynamic change which is used to aid in the formation of cavities within the fluid (cavitation bubbles). When the fluid returns to its initial conditions the cavities then collapse and release a large amount of energy which is absorbed by the fluid rupturing its molecular structure and reorganizing the molecules in a more orderly and stable form for combustion. The intensity in which we create the cavities or cavitation bubbles within the fluid is a function of the system's pressure which also determines the frequency and the intensity of the shock wave that causes the molecular rupture.

During the phenomenon of creation and subsequent collapse of cavities or cavitation bubbles, the process of the present invention reaches up to 500 atmospheres of pressure and hundreds of degrees in temperature, which rupture all polymer chain liquid fluid molecules. This same energy is used to form new polymer chains that are more stable and have better properties for combustion.

Based on the above explanation, it is clear that the reactions happen due to a local increase in the temperature, pressure and the formation of molecular radicals. All of these chemical and physical changes are due to the rupture of the fluid molecular links caused by the collapse of the cavitation bubbles created during the process of cavitation. Depending on the nature of the liquid being cavitated, different effects can be obtained such as: radical creation, depolymerization, Lysis, liquid emulsions, rupture of solid particles, and acceleration of chemical reactions, among others.

FIG. 1 illustrates an embodiment of the present invention used to improve fuel quality as well as volume. The system improves fuels to produce less polluting fuels as well as increasing its final volume The system comprises a dosing and mixing station 104, a hydrodynamic cavitation reactor 106, and a heat exchanger 109. The dosing and mixing station receives fuel from tank 103 which is preheated by a heater 153, as well as water from storage tank 101 and additive from storage tank 102 by means of pumps 141,142,143. Before arriving at the station 104 the various liquids travel through a check valve 121,122,123 and each flow is controlled by volume through an adjustable control flow valve 131,132,133. At the dosing and mixing station 104 liquids are kept in both phases (gas, Liquid) for a predetermined time while a micro emulsion is obtained. After this, the mixture passes through a high-pressure pump where the fluid reaches a high pressure of up to 300 atmospheres. At this high pressure, the fluid enters the hydrodynamic cavitation reactor 106 where cavitation bubbles form and the depolymerization and new polymeric chain formation takes place. After the mixture has been cavitated under pre-established pressure and temperature conditions, the enhanced or treated fuel is stored in the insulated storage tank 111. The treated fuel is cooled in the heat exchanger 109. The chilled fuel is ready to be used or collected through exit valve 107. Since the fuel is cooled in heat exchanger 109, the cooling medium gains enough heat to pre-heat the fuel to be treated, which is stored in the fuel storage tank 103 by means of the recycling of the closed loop system 110 and return through 108.

FIG. 2 illustrates the dosing and mixing station 104 comprising four mixing tanks 221, 222, 223, 224 which receive water through pipe 201, additive through pipe 202 and pre-heated fuel from pipe 203. The mixing that takes place in the tanks 221, 222, 223, 224 occurs by recirculating with a high pressure pump 231, 232, 233, 234. Mixing takes place for a pre-determined amount of time, at such time a computer-controlled valve 241, 242, 243, 244 is opened, allowing the mixed fluid to enter the hydrodynamic cavitation reactor 261, 262. After the mixture has been cavitated under pre-established pressure and temperature conditions, the enhanced or treated fuel is sent through a pipe 270 to the insulated storage tank.

The configuration shown in FIG. 3 provides for a wide range of variables where the volumes of fuel in tank 303 can be combined with volumes of water from tank 301 at a ratio ranging from 1% to 50% under pre-set computer controlled parameters that occur at dosing and mixing station 304. Other additives, such as, but not limited to alcohols (methanol, naphtha, ethanol, etc.) can be mixed as well based on the traits desired to be obtained in the treated fuel. The process initiates with the high pressure mixing pumps 305 recirculating for a predetermined amount of time when it creates a micro emulsion between the different fluids contained in the station 304. At this time a valve is opened and the mixed liquid is sent to the hydrodynamic cavitation reactor 306 where the shock produced by the collapsing cavitation bubbles create temporary active binding centers that recombine including all molecules present at this stage. This one-pass process ensures that the treated fuel will be molecularly stable and will exit to the insulated tank 311, and subsequently pumped by pump 312 through the heat exchanger 309 at which time the cooled fuel would be ready for storage or usage through exit pipe 307.

FIG. 4 illustrates a hydrodynamic cavitation reactor of the present invention. In a preferred embodiment the hydrodynamic cavitation reactor is made from stainless steel. The system comprises a high pressure pump 401, a cavitation valve 402, a Schedule 40 SS 1″ diameter pipe 403, all contained in one module, specifically the valve 402 contains the following zones; liquid entrance zone 404, a cavitation bubble formation zone 405, and a shock zone 406 where the molecular rupture and reorganization occurs.

FIG. 5 illustrates a water and additive storage tank of the present invention. In a preferred embodiment the water and additive storage tank is made from stainless steel. The system comprises an entrance pipe connector 501, a cylindrical tank, among other shapes 502, an exit pipe connector 503, and a support frame 504 when deemed necessary.

FIG. 6 illustrates a heated fuel storage tank of the present invention. In a preferred embodiment the heated fuel storage tank is made from stainless steel. The system comprises an entrance pipe connector 601, a cooling liquid entrance pipe connector 602, a cooling liquid exit pipe connector 603, a cylindrical tank, among other shapes 604, an exit pipe connector 605, and a support frame when deemed necessary.

FIG. 6A illustrates the heater at the fuel storage tank of the present invention. In a preferred embodiment the heater is made from stainless steel. The system comprises an entrance pipe, an exit pipe and a “C” shaped funnel like serpentine that is welded to the embodiment shown in FIG. 6.

In a preferred embodiment the heat exchanger is a shell and tube type heat exchanger as illustrated in FIG. 7. In a preferred embodiment the heat exchanger is made from stainless steel. The system comprises a cooling liquid entrance pipe connector 701, a temperature sensor 702, a treated fuel entrance pipe connector 703, a cooling liquid exit pipe connector 704, a treated fuel exit pipe connector 705, and four baffles 706 to ensure proper heat exchange between fluids.

FIG. 8 illustrates the dosing and mixing station of the present invention. In a preferred embodiment the dosing and mixing station is made from stainless steel. The system comprises a water entrance pipe connector 801, an additive entrance pipe connector 802, a heated fuel entrance pipe connector 803, a cylindrical tank, among other available shapes 805, a mixed fuel/water/additive exit pipe connector 804, all held together with a steel frame.

Although the present invention has been described herein with reference to the foregoing exemplary embodiment, this embodiment does not serve to limit the scope of the present invention. Accordingly, those skilled in the art to which the present invention pertains will appreciate that various modifications are possible, without departing from the technical spirit of the present invention. 

We claim:
 1. A method for molecular rupture and recombination of fuels with additives or fuel enhancers comprising: preheating fuel; mixing said preheated fuel with water and at least one additive until a micro-emulsion mixture is formed; passing said mixture through a pump until a desired pressure is reached; and directing the mixture to a hydrodynamic cavitation reactor where cavitation bubbles are formed and depolymerization and new polymeric chain formation occurs providing modified fuel.
 2. The method of claim 1, wherein said modified fuel is stored in an insulated storage tank.
 3. The method of claim 1, further comprising cooling said modified fuel.
 4. The method of claim 3, wherein said modified fuel is cooled by a heat exchanger.
 5. The method of claim 4, wherein heat generated by the heat-exchanging process is used to preheat said fuel.
 6. The method of claim 1, wherein said fuel comprises diesel fuel mixed with water at a ratio from 1% to 50%.
 7. The method of claim 1, wherein said fuel comprises bunker fuel oil mixed with water at a ratio from 1% to 50%.
 8. The method of claim 1, wherein said fuel comprises gasoline mixed with water at a ratio from 1% to 10%.
 9. The method of claim 6, wherein said modified fuel has increased Cetane levels and provides for levels of CO and CH emissions reduced between 40% and 50%.
 10. The method of claim 7, wherein said modified fuel allows the reduction of emission of: CO by 75%, NO_(x) between 25-50%, and SO₂ between 30-70%.
 11. The method of claim 8, wherein said modified fuel has octane levels improved between 10%-40%.
 12. The method of claim 1, wherein said fuel comprises crude oil and the modified fuel has a decrease in viscosity between 30% and 45% and a gain in API index between 10% and 70%.
 13. A system for molecular rupture and recombination of fuels with additives or fuel enhancers comprising: a supply of fuel; a supply of water; a supply of additives; a dosing and mixing station receiving said supply of fuel, water and additives; and a hydrodynamic cavitation reactor connected to said dosing and mixing station receiving the output of said dosing and mixing station.
 14. The system of claim 13, further comprising: an insulated storage tank connected to said hydrodynamic cavitation reactor.
 15. The system of claim 14, wherein an output of said insulated storage tank is cooled with a heat exchanger.
 16. The system of claim 15, wherein the medium used in the heat exchanger to cool the output of said insulated storage tank is directed to a heater preheating said supply of fuel.
 17. The system of claim 13, wherein said dosing and mixing station comprises: a plurality of mixing tanks each receiving said supply of fuel, water and additives, wherein a high-pressure pump recirculates the mixture.
 18. The system of claim 13, wherein said hydrodynamic cavitation reactor comprises: a high-pressure pump; a cavitation valve connected to said high-pressure pump having a liquid entrance zone, a cavitation bubble formation zone and a shock zone where the molecular rupture and reorganization occurs; and an output pipe.
 19. The system of claim 18, wherein said output pipe comprises a Schedule 40 SS 1″ diameter pipe. 